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R. Petrovi i dr.

Analitika, numerika i eksperimentalna procjena naprezanja kuglastog spremnika velikog obujma

ISSN 1330-3651 (Print), ISSN 1848-6339 (Online)


DOI: 10.17559/TV-20130905131504

ANALYTICAL, NUMERICAL AND EXPERIMENTAL STRESS ASSESSMENT OF THE


SPHERICAL TANK WITH LARGE VOLUME

Radovan Petrovi, Miroslav ivkovi, Marko Topalovi, Radovan Slavkovi

Original scientific paper


This paper presents designing of spherical tank using combination of analytical procedure with FEM analysis and experimental testing in order to
minimize design time and verify design strength. Analytical procedure for calculation of the tank strength in the initial stages of design process is briefly
presented. Based on analytical results, tank is dimensioned and FEM model is created. FEM analysis is used to identify areas with high concentration of
stresses. FEM results showed that equivalent value of stress at the points of spherical tank support exceeds the values of yield stress, but this exceedance is
not significant and in very small area, so overall design was deemed worthy. Experimental measurements verified FEM results that it is not necessary to
reinforce the spherical tank at the points of support. After 8 months experiments were repeated giving the same results as the original measurements, thus
justifying decision not to reinforce tank supports.

Keywords: analytical stress assessment; experimental testing; Finite Element Method (FEM); spherical tank

Analitika, numerika i eksperimentalna procjena naprezanja kuglastog spremnika velikog obujma

Izvorni znanstveni lanak


U radu se opisuje konstruiranje kuglastog spremnika kombinacijom analitikog postupka s FEM analizom i eksperimentalnim testiranjem kako bi se
smanjilo vrijeme konstruiranja i provjerila proraunska vrstoa. Kratko je prikazan analitiki postupak prorauna vrstoe spremnika u poetnim
stadijima konstruiranja. Na temelju analitikih rezultata odreuju se dimenzije spremnika i kreira FEM model. Za prepoznavanje podruja s visokom
koncentracijom naprezanja koristi se FEM analiza. FEM rezultati su pokazali da ekvivalentna vrijednost naprezanja na potpornim tokama spremnika
prelazi vrijednosti granice poputanja, ali to nije znaajno i na veoma je maloj povrini pa se cjelokupna konstrukcija smatra vaeom. Eksperimentalna su
mjerenja potvrdila FEM rezultate da nije potrebno pojaati kuglasti spremnik na potpornim tokama. Nakon 8 mjeseci eksperimenti su bili ponovljeni,
dajui iste rezultate kao i originalna mjerenja i tako potvrdili odluku da se ne pojaavaju potporne toke spremnika.

Kljune rijei: analitika procjena naprezanja; eksperimentalno testiranje; kuglasti spremnik; metoda konanih elemenata (FEM)

1 Introduction hydrostatic pressure [5] and forces that arise due to its
own weight. In addition to these constant loads, other
The spherical tank (Fig. 1) belongs to the group of loads may occur due to the action of wind force [6], snow
stable elevated tanks designed for storing butane, propane [7] as well as seismic loads [8, 9]. To prevent leakage or
or mixture of propane-butane with medium pressure fire of those hazardous gases, detection of damage in tank
[13]. structure is crucial [5]. However, good tank design, and
adhering to safety protocols can prevent critical damage
from ever occurring in tank structure. To ensure there are
no flaws in their design, engineers cannot rely solely on
analytical results, they need to verify their design by
numerical simulations and experimental testing as well,
which is methodology presented in this paper.
Well known analytical procedure used in designing
spherical tanks is briefly explained [10]. Detailed
derivation of expressions for membrane forces and
stresses in the direction of the tangent to the circle of the
parallel and the meridian using the membrane state of
stress and equilibrium equations for the shell in the form
of surface of revolution is given in [11]. Analytical
solution is used in the initial phase of design because the
basic dimensions of the spherical tank can be obtained in
a relatively short period of time [10], but this solution
does not account for specificity of areas with high
concentration of stress, such as points of connection
between tank and its supports, and therefore more detailed
numerical analysis is required in order to be certain that
proposed design will meet safety criteria. This analysis is
done using Finite Element Method (FEM) and its results
Figure 1 Spherical tank V=1000 m3 show that equivalent value of stress at some points
exceeds the values of yield stress. Areas of plastic
These highly flammable gases need to be stored in deformation are not significant in comparison to the entire
tanks designed with safety as their upmost priority [4]. spherical tank construction, so based on FEM results it is
The spherical tank is loaded with the fluid pressure, concluded that cumulating of plastic deformation will not

Tehniki vjesnik 22, 5(2015), 1135-1140 1135


Analytical, numerical and experimental stress assessment of the spherical tank with large volume R. Petrovi et al.

occur. Since FEM results should always be used with 2 Methods


caution, having in mind that their accuracy depends on 2.1 Analytical procedure
number of factors such as mesh quality, proper
constraints, loads and boundary conditions, experimental Stress state in elements of the shell in the form of
verification of FEM results in the most critical areas of surface of revolution can be determined by Equilibrium
the tank structure was required in order to verify equations for the shell elements.
conclusions drawn from FEM results. Achieved high level Forces acting on the element which is a part of shell
of correspondence between results obtained analytically, in the form of surface of revolution are presented in
with FEM analysis, and with experimental tests of Figure 2. The element is defined by two parallel circles,
spherical tank show that the proposed design meets safety with radiuses r0 and r0+dr0, and two adjacent meridians
standards. After eight months of exploitation, determined by the angles and +d. Position of the
experimental testing was repeated, and no changes in element belonging to the shell in the form of surface of
stress values were observed. Combination of analytical revolution for spherical tank is shown in Fig. 2a as well as
procedure with FEM analysis and experimental testing of components of the external surface load , , . Fig. 2b
spherical tank gives more detailed insight in behavior of shows internal forces acting on that element [10, 11]. The
tank construction in most critical areas in comparison to tank operates in moderate climate conditions, so
design process which rely solely on analytical results and temperature influence can be neglected [12].
thus ensuring optimum design and safe usage during
envisioned operating life time.

Figure 2 a) Position of the shell in the form of surface of revolution element, b) Internal forces in the element of the shell in the form of surface of
revolution

According to [11], equilibrium equations for the shell Equilibrium equation for shell section is given by
element are given with: 2 RN sin 2 + Q = 0 , (4)

N ( N r0 )
r1 + N r1cos + + Xr0 r1 = 0 , where Q represents resultant of external loading.

(1) 2.1.1 Own weight loading
N ( N r0 )
r1 N r1cos + + Xr0 r1 = 0 , (2) The load on the spherical tank due to its own weight

is shown in Fig. 4.
N N Position of tank supports is defined by angle 0 (Fig.
+ = Z . (3)
r2 r1 4).
Internal forces due to tank own weights above
supports are:

gR
N = , (5)
1 + cos
1
N = gR cos . (6)
1 + cos

Internal forces due to tank own weight below


Figure 3 Equilibrium of the shell section
supports are:
Equilibrium between internal forces and external load
acting on shell section is shown in Fig. 3.

1136 Technical Gazette 22, 5(2015), 1135-1140


R. Petrovi i dr. Analitika, numerika i eksperimentalna procjena naprezanja kuglastog spremnika velikog obujma

gR The operating pressure in the tank is: pg = 1,67 MPa.


N = , (7) For safety reasons, experimental testing was performed
1 cos
with water ( = 9810 N/m3) instead of propane-butane
1 mixture. Analytical calculation and FEM simulations
N = gR cos . (8)
1 cos were also done with water in order to obtain comparable
results. Using (713) and expressions for stresses:

N N
= , = , (14)

corresponding values of forces and stresses for different


angles are obtained. The total value of stresses can be
calculated by adding the own weight and internal pressure
components. The resulting values are presented in Tab. 1
and Fig. 5.

Table 1 The stresses due to own weight and internal pressure


Angle / / MPa / MPa e / MPa
0 185,3 185,3 185,3
10 185,4 185,5 185,4
Figure 4 Own weight loading of the spherical tank 20 185,5 185,9 185,7
30 185,8 186,7 186,2
40 186,1 187,8 186,9
2.1.1 Internal pressure loading
50 186,5 189,1 187,8
60 186,8 190,7 188,8
Spherical tank supported along a parallel circle B-B
70 187,2 192,5 189,9
(Fig. 4) and filled with liquid which has specific weight , 80 187,5 194,5 191,1
is loaded with pressure: 90 187,6 196,8 192,4
100 196,9 189,9 193,5
p = Z = gR(1 cos ) + p g , (9) 110 197,2 191,9 194,6
120 197,6 193,7 195,7
where pg represents uniformed pressure superposed on 130 198,0 195,3 196,6
140 198,3 196,6 197,5
hydrostatic pressure [11].
150 198,6 197,7 198,2
Internal forces due to hydrostatic pressure and
160 198,9 198,5 198,7
internal gas pressure above supports are: 170 199,0 198,9 199,0
180 199,1 199,1 199,1
gR 2 2cos 2 Rp g
N = 1 + , (10)
6 1 + cos 2

gR 2 2cos 2 Rp g
N = 5 6cos + + . (11)
6 1 + cos 2

Internal forces due to hydrostatic pressure and internal


gas pressure below supports are:

gR 2 2cos 2 Rp g
N = 5+ + , (12)
6 1 cos 2

gR 2 2cos 2 Rp g
N = 1 6cos + . (13)
6 1 cos 2

2.2 Finite element simulation

Verification of analytical expressions using finite


Figure 5 Distribution of values of the equivalent stress of the spherical
element method was performed for the spherical tank with tank obtained analytically
volume V = 1000 m3, external diameter D = 12.456 mm,
wall thickness =28 mm, [1316]. The tank is made of The 3D model of the spherical tank was formed by
steel whose yield stress is: synthesis of 3D models of all structural parts [1720].
The model represents a continuum discredited by 10-node
f y = REH = 419 N/mm 2 . tetrahedral elements for the purpose of creating the FEM
model (45.124 nodes. 25.016 elements). The equivalent

Tehniki vjesnik 22, 5(2015), 1135-1140 1137


Analytical, numerical and experimental stress assessment of the spherical tank with large volume R. Petrovi et al.

stress field is presented in Fig. 6. The distribution of absolutely certain that plastic deformations in supports
equivalent stresses of the FEM analysis corresponds to the will not cause failure of the structure.
distribution of stresses obtained by analytical calculation.
The highest values of stresses were obtained at the
points of support of the spherical tank (Fig. 7) [20].

Figure 8 Deformations of the spherical tank

2.3 Experimental verification


Figure 6 Distribution of values of the equivalent stress of the spherical
tank by using the FEM model Verification of analytical and the results obtained
using the FEM model was performed by experimental
testing of the spherical tank. As stated in previous section,
for safety reasons, experiments were performed with
water instead of propane-butane mixture.

Figure 9 Layout of the measuring points

The experiment was carried out by measuring stresses


Figure 7 Distribution of the equivalent stress of the spherical tank at the
at 7 measuring points with 21 strain gauges, by using the
points of support measuring equipment HBM UPM 100 [21]. The layout of
the measuring points is shown in Fig. 9. This type of
These values are higher than yield stress and could strain gauges setup makes measuring easier and does not
cause failure of tank supports. Since the area of this high require knowledge of the direction of the principal
stress concentration is very small it is concluded that the stresses propagation.
overall strength of supports will not deteriorate with time The strain gauges placed on spherical tank are shown
due to cumulating of plastic deformation. Deformations of in Fig. 10.
the spherical tank are presented in (Fig. 8). Since FEM
analysis identified dangers in the proposed design,
experimental verification was needed in order to be

1138 Technical Gazette 22, 5(2015), 1135-1140


R. Petrovi i dr. Analitika, numerika i eksperimentalna procjena naprezanja kuglastog spremnika velikog obujma

from the results obtained analytically and by using the


FEM model in relation to the results obtained
experimentally are presented in Tab. 5.
Stress values obtained by experiments for some
measuring sites are higher than analytical or FEM
calculated stress, while for other sites they have lower
value as shown in Tabs. 2 and 4. This disagreement is
proof that experimental verification is necessary in order
to be certain that proposed design will meet all safety
requirements.

Table 5 Percent deviation of equivalent stresses obtained analytically


and by FEM model in relation to the results obtained experimentally for
the test pressure
Deviation of results
Figure 10 Strain gauges placed on measuring points MM4MM7
Measuring Deviation of results
obtained
site obtained by using FEM / %
analytically / %
3 Results and discussion MM1 8,0 6,7
MM2 8,2 4,8
The comparative values of stresses, for the operating MM3 6,7 5,7
pressure of 1,67 MPa, obtained analytically at the MM4 - 8,1
characteristic points, by FEM model and experimentally, MM5 1,9 6,0
are presented in Tab. 2. MM6 12,6 0,2
MM7 11,2 0,8
Table 2 The comparative values of stresses obtained analytically, by
FEM model and experimentally From Tabs. 3 and 5 it can be clearly seen that FEM
Measuring e / MPa e / MPa e/ MPa results are more accurate than analytical results in
site Analytical FEM Experiment comparison to values obtained by experiments. FEM
MM1 185,3 183,5 169,6 analysis is also much cheaper than construction and
MM2 192,4 190,1 175,6 testing of prototype, it can identify critical areas and, if
MM3 199,1 197,0 182,3 needed, modifications of design are easily and quickly
MM4 - 334,8 343,1
conducted, so when prototype is constructed experiments
MM5 194,6 199,5 201,0
are used to verify design and no further modifications on
MM6 195,7 194,3 180,1
MM7 196,6 195,4 182,3
tank design are needed. In the case of analysed spherical
tank the equivalent values of stresses at the point MM4
exceeded the values of yield stress, but not across the
Tab. 3 presents the percent deviation from the values
whole section (Fig. 7). The areas of local plastic
of equivalent stresses obtained analytically and by FEM
deformation associated with stress concentrations are
model in relation to the results obtained experimentally.
sufficiently small so there is no significant permanent
Table 3 Percent deviation of equivalent stresses obtained analytically deformation when the load is removed. Stress
and by using the FEM model in relation to the results obtained concentration predicted by FEM was also registered by
experimentally experimental testing. Tank design was proved to be
Measuring Deviation of results Deviation of results reliable, namely, because the measured values of
site obtained analytically / % obtained by FEM / % equivalent stresses are, after eight months of exploitation
MM1 9,3 8,2 (Tab. 2 and Tab. 4), identical to the original values after
MM2 9,6 8,3
the installation of the spherical tank and its putting into
MM3 9,2 8,1
operation.
MM4 - 2,4
MM5 3,2 0,7
MM6 8,7 7,9 4 Conclusion
MM7 7,8 7,2
The research carried out showed a high level of
Table 4 The equivalent values of stresses for the test pressure correspondence of the results obtained analytically and by
Measuring e / MPa e / MPa e / MPa FEM model with the results of experimental testing of
site Analytical FEM Experiment spherical tanks. This correspondence of the results allows
MM1 277,4 274,1 256,9 analytical expressions to be used for dimensioning
MM2 284,4 250,3 262,9 spherical tanks. It is particularly important because, in a
MM3 291,2 288,5 272,9 short period of time, in the initial design phase, the basic
MM4 - 444,1 483,4 dimensions of the spherical tank can be obtained without
MM5 287,8 265,5 282,3 carrying out an experiment and without FEM modeling.
MM6 289,6 257,9 257,3 After the initial design phase, when all tank dimensions
MM7 290,8 259,6 261,6
are known, more accurate FEM analysis is used to
identify areas of high stress concentration. In the case of
The equivalent values of stresses for the test pressure analyzed tank for pressure of 2,5 MPa equivalent stress
of 2,5 MPa are presented in Tab. 4, and the deviations exceeds yield stress at the points of tank connection with

Tehniki vjesnik 22, 5(2015), 1135-1140 1139


Analytical, numerical and experimental stress assessment of the spherical tank with large volume R. Petrovi et al.

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